Power supply system with wire harness for interconnecting individual power supply modules

ABSTRACT

A power supply system includes modular power supply modules interconnected via a wire harness. The power supply system can be installed in one or more electrical cabinets in a manufacturing facility, for example, among other possible applications. The wire harness includes a fault bus and a synchronization bus, and the individual power supply modules detect and report faults as well as synchronize operation, such as pre-charging, via communication using the wire harness.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application claims priority to and the benefit of the filing dateof U.S. Provisional Patent Application No. 63/362,761, filed Apr. 11,2022, the entire contents of which is incorporated by reference herein.

BACKGROUND

The present disclosure generally relates to a power supply system andassociated circuitry and functionality. The power supply system can beused for industrial applications, such as provided in one or moreelectrical cabinets in a manufacturing facility. The power supply systemcan provide power to machinery and/or associated control components,such as electric motor drives and other electronic control components.The power supply system generally includes multiple interconnected powersupply modules, that can be provided in different configurations fordifferent applications.

There are several considerations when integrating parallel powerstructures. For example, a conventional power module can have onlydiscrete (on/off) inputs and outputs, such that there can be no typicalserial communication link outside of the module. Consequently, the onlyuser configuration of the module can be through DIP-switch settings.Furthermore, each power module can have near-autonomous operation, whileallowing for parallel configuration, with no central system controllerto coordinate operation.

Other integration considerations include safety standards (e.g., ULstandards) that can require that certain faults shut down all parallelpower modules in a system. Still another consideration includespre-charging that is open loop without current sensors, ensuring thatall power modules have the same configuration switch settings, andsynchronizing the start time of the pre-charge. Each power supply modulecan have a local internal power supply. Direct connection of interfacesignals between them has a high risk of common mode noise issues. Priorattempts, such as using a separate system power supply for the onlyinterface signal, can create inefficiencies and be disadvantageous dueto cost and configuration complexities.

The use of one of the parallel power modules as a single designatedsource of power can also be disadvantageous due to N−1 operation being aproduct requirement, such that if the “master” module fails and requiresremoval, reconfiguration of the system to a new master is required.Another challenge can be that avoiding security certificationrequirements for product release can require no non-volatile memory ofsystem configuration or history. Consequently, the system can have tofigure out its configuration on every power cycle.

SUMMARY

One aspect of the disclosure provides a power supply system including afirst power supply module, a second power supply module, and a wireharness that connects the first power supply module and the second powersupply module. The first power supply module includes a first faultinput terminal, a first fault output terminal, and a firstsynchronization terminal. The second power supply module includes asecond fault input terminal, a second fault output terminal, and asecond synchronization terminal. The wire harness includes asynchronization bus and a fault bus. The synchronization bus isconnected to the first synchronization terminal and the secondsynchronization terminal. The fault bus connects the first fault outputterminal to the second fault input terminal and the second fault outputterminal to the first fault input terminal.

Another aspect of the disclosure provides a power supply systemincluding a first power supply module, a second power supply module, athird power supply module, and a wire harness that connects the firstpower supply module, the second power supply module, and the third powersupply module. The first power supply module includes a first faultinput terminal, a first fault output terminal, and a firstsynchronization terminal. The second power supply module includes asecond fault input terminal, a second fault output terminal, and asecond synchronization terminal. The third power supply module includesa third fault input terminal, a third fault output terminal, and a thirdsynchronization terminal. The wire harness includes a synchronizationbus and a fault bus. The synchronization bus is connected to the firstsynchronization terminal, the second synchronization terminal, and thethird synchronization terminal. The fault bus connects the first faultoutput terminal to the second fault input terminal, the second faultoutput terminal to the third fault input terminal, and the third faultoutput terminal to the first fault input terminal.

Yet another aspect of the disclosure provides a power supply systemincluding a first power supply module, a second power supply module, anda wire harness that connects the first power supply module and thesecond power supply module. The first power supply module includes afirst fault input terminal, a first fault output terminal, and a firstsynchronization terminal. The second power supply module includes asecond fault input terminal, a second fault output terminal, and asecond synchronization terminal. The wire harness includes asynchronization bus and a fault bus. The synchronization bus isconnected to the first synchronization terminal and the secondsynchronization terminal. The fault bus connects the first fault outputterminal to the second fault input terminal and the second fault outputterminal to the first fault input terminal. The first power supplymodule include circuitry for asserting a first synchronization signal onthe synchronization bus. The second power supply module includecircuitry for asserting a second synchronization signal on thesynchronization bus.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the presentdisclosure can become better understood when the following detaileddescription is read with reference to the accompanying drawings in whichlike characters represent like parts throughout the drawings, wherein:

FIG. 1 is an example schematic illustration of a power supply systemconnecting two separate power supply modules via a fault bus, accordingto some aspects of the disclosure.

FIG. 2 is an example schematic illustration of an impedance isolatedwire-or synchronization power supply circuit, according to some aspectsof the disclosure.

FIG. 3 is an example schematic illustration of a power supply systemconnecting three separate power supply modules via a synchronizationbus, according to some aspects of the disclosure.

FIG. 4 is an example illustration of different components of a wireharness for a power supply system, according to some aspects of thedisclosure.

FIG. 5 is an example illustration of a bypass jumper that can be usedwith a wire harness for a power supply system, according to some aspectsof the disclosure.

FIG. 6 is an example illustration of a loopback jumper that can be usedwith a wire harness for a power supply system, according to some aspectsof the disclosure.

FIG. 7 is an example illustration of a coupler that can be used with awire harness for a power supply system, according to some aspects of thedisclosure.

FIG. 8 is an example illustration of an adapter that can be used with awire harness for a power supply system, according to some aspects of thedisclosure.

FIG. 9 is an example illustration of a wiring bay pass-through devicethat can be used with a wire harness for a power supply system,according to some aspects of the disclosure.

FIG. 10 is an example illustration of a power supply system including asingle power supply module and a wire harness, according to some aspectsof the disclosure.

FIG. 11 is an example illustration of a power supply system includingtwo power supply modules and a wire harness, according to some aspectsof the disclosure.

FIG. 12 is an example illustration of a power supply system includingtwo power supply modules, a wiring bay, a thermal switch, and a wireharness, according to some aspects of the disclosure.

FIGS. 13A-13D provide an example illustration of a power supply systemincluding six power supply modules and a wire harness, according to someaspects of the disclosure.

FIGS. 14A-14D provide an example illustration of a power supply systemincluding five power supply modules, a bypass jumper, and a wireharness, according to some aspects of the disclosure.

DETAILED DESCRIPTION

The present disclosure provides a power supply system and associatedcircuitry and methods of operation. The power supply system can includemultiple power supply modules that are interconnected using a wireharness. The wire harness can include various components and caninterconnect the power supply modules in a daisy chain configuration.The wire harness can include both a synchronization bus and a fault bus.The synchronization bus can provide a wire- or connection between thepower supply modules in the power supply system, such that a concurrentprecharge process can be implemented responsive to each of the powersupply modules asserting a synchronization signal on the synchronizationbus. The fault bus can be used to detect both system and device levelfaults, and can be connected to different terminals of the power supplymodules in different configurations. The power supply modules generallyuse circuitry including optocouplers (opto-isolators), resistor bridges,and transistors to assert synchronization signals, read synchronizationsignals, and provide indications of faults within the power supplysystem. One or more aspects of the disclosure are provided in thePowerFlex 755TM Non-Regenerative Supply (NRS) product offering providedby Rockwell Automation (Allen-Bradley), among other possible productofferings.

One or more specific aspects of the disclosure will be described below.In the interest of providing a concise description of these aspects, notall features of an actual implementation are described in thespecification. It should be appreciated that in the development of anysuch actual implementation, as in any engineering or design project,numerous implementation-specific decisions are made to achieve thedevelopers' specific goals, such as compliance with system-related andbusiness-related constraints, which can vary from one implementation toanother. Moreover, it should be appreciated that such a developmenteffort might be complex and time consuming, but would nevertheless be aroutine undertaking of design, fabrication, and manufacture for those ofordinary skill having the benefit of this disclosure.

In some aspects of the disclosure, a system and method of interfacingparallel power structures as described herein can include the same typeof discrete wire interface harnesses that are already being utilized ina system cabinet for control power distribution. The system and methodcan be implemented without a separate system controller and withoutrequiring the individual power structures to remember the systemconfiguration in non-volatile memory. The system and method can utilizewiring harness interconnection logic to meet agency safety requirementsfor system fault shutdown with fail-safe for open connections. Thesystem and method can allow N−1, N−2, etc. operation that validatesremoval of the faulty unit by wiring harness interconnection logic. Thesystem and method can enable parallel structures to recognize andvalidate the system configuration at power-up. The system and method canenable timing synchronization between parallel units. The system andmethod can provide testing integrity of synchronization interconnectionsat power-up.

The system and method can provide common-mode noise immunity frominteraction between parallel power structures without requiring aseparate system power supply by utilizing two distinct methods,including a daisy-chain wire harness interconnection scheme thatprovides full galvanic isolation of each link (used for configurationverification and fault handling), and an implementation of a wire-orinterconnection using impedance isolation for interfacing signals withmultiple power sources (used for pre-charge synchronization).

A modular cabinet harness system and method can be provided. A systemand method for interfacing parallel power structures can include adaisy-chain wire harness interconnection scheme that provides fullgalvanic isolation of each link. The daisy-chain wire harnessinterconnection scheme can be configured for verification and faulthandling. A system and method for interfacing parallel power structurescan include an impedance isolated wire-or circuit. The impedanceisolated wire-or circuit can be configured for pre-chargesynchronization. The system and method can be configured to increase thenumber of conductors in existing discrete-wire interconnect cabling. Thesystem and method can be configured to provide isolation fromcommon-mode interaction between parallel power modules without requiringa separate interface power supply or requiring a module to be designatedas a master.

The system and method can be configured to provide interface signalnoise immunity from system power cabinet noise interference. The systemand method can be configured to provide a single pre-installed cabinetwiring harness by utilizing various inter-cabinet coupling and loop-backlinks. The system and method can be configured to provideself-configuration and can be configured to support UL standard andother safety fault shut-down requirements. The system and method can beconfigured for interfacing cabinet overtemperature detection withoutrequiring additional interface I/O. The system and method can beconfigured to synchronize open-loop pre-charge of parallel powermodules. The system and method can be configured to controlimpedance-isolated wire-or current signaling logic through a pair ofwires with a variable number of module taps. The system and method canbe configured for power-up configuration verification. The system andmethod can include a low-speed asynchronous communication scheme througha daisy chain interface that can determine the number of modules andtheir position in the chain based on passing unique serial numbersthrough the chain. The scheme and method can be configured to supportverification of the wire-or synchronization circuit.

Referring to FIG. 1 , a power module system 10 is shown. The powermodule system 10 can include harness interconnection logic between afirst power Module A and a second power Module B. The power modulesystem 10 can be configured for fault handling and configurationverification. Power module system 10 as illustrated in FIG. 1 providesan example of an interconnection between two power supply modules in apower supply system for detecting and indicating faults throughout thesystem. A fault input terminal of Module A is connected to a faultoutput terminal of Module B via a wire harness 12. The fault inputterminal of Module B can then be connected to a fault output terminal ofa third power module C (not shown). The fault output terminal of ModuleA can also be connected to a fault input terminal of a fourth module D(not shown), and so on. The connections between fault input and outputterminals of the individual power supply modules can be formed viaconnection to a fault bus of wire harness 12, where the fault bus isused by the individual power supply modules and the power supply systemmore generally to indicate faults that can occur.

Agency certification (e.g., meeting UL safety standards) can requirethat certain faults cause all parallel modules, e.g., modules A, B, ofthe power module system 10 to stop. Examples of faults can include buscapacitor bank imbalance, AC fuse open, DC fuse open, busbarovertemperature (e.g., applies to wiring bay), and failure of amonitoring system for various types of faults. Monitoring of faults caninclude monitoring for bad contacts or unplugged connections in wireharness 12, loss of control power in the power modules, and anon-operational field-programmable gate array (FPGA) or associatedcomponents of the main control board in an individual module. Mismatchedconfiguration switch settings or voltage ratings of parallel units,harness interconnection failure, or phase-locked loop (PLL) loss duringpre-charge can also cause a hard fault. Other faults can stay local to agiven module, such that stopping other parallel modules may not berequired.

FIG. 1 shows wire harness 12 forming a daisy chain structure forconnecting Module A and Module B, however as noted any number of powermodules can be used to provide varying levels of power supply. Each linkin the daisy chain can be powered by the module receiving the signal.For example, Module A is shown to include its own individual powersupply 14, which can be used along with the illustrated circuitcomponents to provide full galvanic isolation at the receiving module.While the individual power supplies in FIG. 1 are shown to be 48V, itshould be noted that different types and magnitudes of local powersupplies can be used with the power supply systems and modules describedherein, depending on the intended application. A differential wire paircontrolling an optocoupler 18 (a first wire connected to a firstterminal of optocoupler 18 as illustrated, and a second wire connectedto a second terminal of optocoupler 18 as illustrated) with current (asopposed to voltage) is used for noise immunity in the power supplysystem cabinet where Module A and Module B are installed. The diodes(D1) shown in FIG. 1 can be used to limit the maximum voltage acrossthermal switches in the electrical cabinet.

The wire harness 12 can include building block components and harnesslinks that self-orientate when the power module system 10 is assembled.When the last module in the system 10 is reached, the harness assembly12 can loop the interconnect back to the first module in a daisy chainfashion. The wire harness 12 can fault due to an open connection in thechain. This behavior can allow a secondary function to detect systemovertemperature sensing by routing the chain through one or morenormally closed thermal switches (overtemperature switches) that open athigh temperatures. This functionality can allow the power supply systemto respond to possible hazards that can occur within one or moreelectrical cabinets in which the power supply system is installed, suchas fires, excessive voltage, or excessive current within the powersupply system and/or other electrical components in the one or moreelectrical cabinets.

At power-up, the wire harness 12 can also be used for low-speed serialcommunication to verify that the configuration switches (e.g., DIPswitches) of all parallel Modules A, B have matching settings. Theunique manufacturing serial number of each power supply module can betransmitted through the wire harness 12 at power-up. This functionalitycan allow each power supply module to identify the other modules in thepower supply system, which can enable testing of a synchronizationbetween the power supply modules connected to the wire harness 12. Thepower supply system can allow N−1, N−2, etc., operation down to a singleremaining module. To allow this functionality, bypass jumpers can bepre-installed in the one or more system cabinets that complete the pathof the wire harness when any individual power supply module is removedfrom the daisy chain. These bypass jumpers can be positioned so that thewire harness can be unable to connect to them when the correspondingpower supply module is in place. If a non-parallel system isimplemented, the output of a single power supply module can loop back toits own input through the system harness.

As shown in FIG. 1 , the hard fault output of Module B (BFO1, BFO2) iscascaded to the cabinet fault input of Module A (AFI1, AFI2) via thewire harness 12 (e.g., via the fault bus of wire harness 12). The signalprovided via these input and output terminals can be provided via acurrent loop circuit using a pair of wires between optocouplers, asshown in FIG. 1 . Power for these current loops within the power supplysystem can be provided by the receiving power supply module (e.g., bythe local power supply 14). The current loop pair can be over the sametype of discrete wire harness that is used for 240V system power.

Full galvanic isolation between Module A and Module B can be providedvia the circuitry illustrated in FIG. 1 , where full galvanic isolationprevents common mode noise interaction between the power supply modules.The current loop can provide a high level of noise immunity for signalrouting inside of the one or more system power cabinets. By definingthat the de-energized optocoupler equals a fault condition, theinterface can provide a fail safe for open connections. The fault signalcan be routed through thermal switches (overtemperature switches) todetect cabinet overtemperature conditions. Low-speed asynchronous serialcommunication can be transmitted through these links at initialpower-up. Afterwards, they can function as a static on/off fault signal.In an example of system operation, communication through the faultcircuit can occur as shown in the state machine process flows below. Itwill be appreciated that these state machine process flows are providedas examples, and modifications to their operation are possible andcontemplated.

Data Comms State Machine

-   -   1) Allow for any board-to-board powerup time variation    -   2) Assemble local data packet for subsequent transmission and        comparison to subsequent received data packets        -   a. Serial number        -   b. Configuration bits        -   c. Calculated CRC (Cyclic Redundancy Check), using a            suitable polynomial for data packet    -   3) Enable UART RX    -   4) Wait for powerup module timer to expire    -   5) Enable UART TX state machine    -   6) Loop        -   a. Transmit data            -   i. For first iteration transmit board's data            -   ii. After first iteration, forward most recently                received RX data        -   b. Wait for TX data complete        -   c. Wait for RX data complete        -   d. Perform CRC testing on RX data and set fault if            appropriate        -   d. Update serial number order as necessary        -   e. Update roll-in count as necessary            -   i. If >6, set roll-in count fault        -   f. If RX serial number matches serial, data comms complete    -   7) Data comms complete

UART TX State Machine

-   -   1) Transmit bits per Data Comms State Machine    -   2) Transmit bits at an appropriate rate and of appropriate group        sizing to ensure data integrity due to various influences such        as signal edge rates, clock frequency differences, noise, etc.        -   a. Start bit        -   b. Data bit(s)        -   c. Parity bit        -   d. Stop bit        -   e. Wait for completion    -   3) Repeat until entire data packet sent

UART RX State Machine

-   -   1) Receive data per Data Comms State Machine    -   2) Start a watchdog timer to prevent possible lockup condition        -   a. Disable the watchdog timer once entire data packet is            received        -   b. If entire data packet is not received within a timeout,            set a fault    -   3) Loop until entire data packet is received        -   a. Detect start bit            -   i. Start a bit timer watchdog timer to prevent possible                lockup condition            -   ii. Take multiple data samples near expected middle of                bit period and determine if polarity is expected value            -   iii. The ratio of received polarity can be used to                indicate presence of noise            -   iv. If the bit timer watchdog expires, set an alarm        -   b. Sample data bit(s)            -   i. Take multiple data samples data near expected middle                of bit period and determine polarity            -   ii. The ratio of received polarity samples can be used                to indicate presence of noise            -   iii. Continue for expected number of data-bits        -   c. Sample parity bit            -   i. Take multiple data samples data near expected middle                of bit period and determine polarity            -   ii. The ratio of received polarity samples can be used                to indicate presence of noise        -   d. Calculate/compare parity bit            -   i. If received parity is not equal to calculated parity,                set a fault        -   c. Detect stop bit            -   i. Take multiple data samples data near expected middle                of bit period and determine polarity            -   ii. The ratio of received polarity samples can be used                to indicate presence of noise

Referring now to FIG. 2 , an impedance isolation wire-or power supplycircuit 20 is shown. The impedance isolation wire-or circuit 12 can beconfigured to provide synchronization and common-mode noise immunity.Power supply modules can use an open loop timing sweep for pre-charging.There may be no current feedback to limit the output current ofindividual modules. The power module can have a synchronized start (maxone line-cycle variation) to prevent the first module to start having anexcessive load. The pre-charge sweep rate switch settings on allparallel modules can match. The pre-charge synchronization and interfacesystem (e.g., the impedance isolation wire or circuit) can be differentfrom the daisy-chain interconnection used for fault handling andconfiguration.

At power up for the impedance isolated wire-or circuit 20, each parallelpower module can assert the wire-or synchronization signal. Generally,as each module completes its initialization, it can de-assert control ofthe synchronization signal. When the last module releases thesynchronization signal, all modules can commence pre-charge at the sametime (concurrent precharge process). The synchronization signal can beprovided via a pair of wires bridging a resistor divider at each module.Each power module's resistor divider can contribute power to thesynchronization pair, and thereby eliminate the need to designate onemodule as the power source or having a separate power supply. Theresistor strings can limit the common-mode current interaction betweenmodules. Each power module can have a first optocoupler to assert thesynchronization signal. Each module can also have a second optocouplercircuit including a field effect transistor to read the status of thesynchronization signal. Because the synchronization signal can be drivenby current signaling (as opposed to voltage), it can offer improvednoise immunity in the system cabinet. If there is only one module(non-parallel system), it can start as soon as it de-asserts its ownsynchronization signal. Once pre-charge has commenced, thesynchronization signal can be unused until another pre-charge sweep isrequired.

As shown in FIG. 2 , the power supply circuit 20 includes a firstoptocoupler 22 for asserting the wire-or (synchronization signal) and atransistor 27 controlling the second optocoupler 24 for reading thestatus of the wire-or (synchronization signal). When energized, thefirst optocoupler 22 completes the circuit of a first resistor ladder 26as shown in FIG. 2 . The first resistor ladder 26 includes a firstsection (R1 and R5) connected to the local power supply voltage and to afirst terminal (terminal 4) of the first optocoupler 22. While the localpower supply voltage in FIG. 2 is shown to be 48V, it should be notedthat different types and magnitudes of local power supplies can be useddepending on the intended application. The first resistor ladder 26 alsoincludes a second section (R2, R3, R4) connected to a reference voltage(GND, ground), a second terminal of the first optocoupler (terminal 3),and a transistor 27. The power supply circuit includes a first wire 28 aconnected to the first optocoupler 22 and a second wire 28 b alsoconnected to the first optocoupler 22. The first wire and the secondwire are shown to form a wire pair 28. The first wire 28 a is connectedto the first terminal of the first optocoupler 22 and to the firstsection of the first resistor ladder 26, and the second wire 28 b isconnected to the second terminal of the first optocoupler 22 and to thesecond section of the first resistor ladder 26. The first wire 28 a andthe second wire 28 b can be used to provide the synchronization signalfor the power supply module to the synchronization bus of the powersupply system on the synchronization terminal of the power supply moduleas a current signal responsive to the first optocoupler 22 beingenergized.

As shown in FIG. 2 , the power supply circuit 20 also includes a secondresistor ladder 29 connected to a first terminal (terminal 1) of thesecond optocoupler 24. The second resistor ladder 29 is connected to thelocal power supply voltage and is shown to include five separateresistors. Multiple separate resistors can be used in the resistorladder 29, as opposed to using a single resistor, to preventshort-circuit failure mode of an individual resistor from causing thesafety-limiting values of the second optocoupler 24 from being exceeded(e.g., protecting a 3.3V synchronization status from electrical damageresulting from a 48V supply). The transistor 27 is also shown to beconnected to a second terminal of the second optocoupler 24 (terminal2). The transistor 27 in some implementations is a field effecttransistor (FET), where the gate terminal of the FET is connected to thesecond section of the first resistor ladder 26, the source terminal ofthe FET is connected to the reference voltage (ground), and the drainterminal of the FET is connected to the second terminal of the secondoptocoupler 24. It will be appreciated that the magnitudes of theimpedance provided by each of the resistors shown in the first resistorladder 26 and the second resistor ladder 29 can be varied and/ordifferent quantities of resistors can be used, depending on the intendedapplication.

In general, the resistors in the first resistor ladder 26 can provideenergy to the wire pair 28, while providing impedance to blockcommon-mode noise between power supply modules interconnected in a powersupply system configuration. The power supply circuit 20 can optionallybe connected in parallel to additional modules through the cabinetharness, in which case all modules are providing energy. The optocouplerfrom one power module can be sufficient to complete the resistor laddercircuits of multiple modules. In some examples, up to six power supplymodules can be used in a power supply system. Synchronization signalwire pairs can use current signaling (as opposed to voltage signaling)for immunity to noise in the system cabinet. The transistor 27 can beused to detect voltage drops across the resistor ladders so that thesynchronization status optocoupler 24 does not impact the load currentthrough the resistor ladders. Given the sensitive nature of the logiccircuits used to control the sync control and sync status signals, it isimportant to protect these circuits from outside noise interference. Insome implementations, use of a 48V power supply can allow higherresistance values to be used for the resistors (in the first resistorladder 26 and the second resistor ladder 29) while still maintainingadequate current for the first optocoupler 22 and the second optocoupler24.

FIG. 3 shows another example power module system 30. Power module system30 includes three separate modules connected to a synchronization bus aspart of a power supply system. Each of Module A, Module B, and Module Cas shown in FIG. 3 include the impedance isolated wire-or circuit 20described above for asserting and de-asserting respectivesynchronization signals on the synchronization bus, and reading thestatus of the respective synchronization signals. FIG. 3 illustrates anexample of how the synchronization terminals of each power supply moduleincluding the synchronization wire pairs are interconnected via thesynchronization bus in the system cabinet wire harnessing.

If an open interconnection in the wire harness exists, one or moremodules can operate independently without waiting for all modules to beready before commencing a concurrent precharge process. Asynchronization system integrity verification test can be implemented atpower-up to protect against these types of situations. In the event ofopen interconnections in the wire-or implantation, this condition canallow non-synchronized pre-charge, with imbalance current betweenmodules. To prevent this situation, the integrity of the synchronizationharness system can be tested at power up. The unique manufacturingserial number of each module can be transmitted through the daisy chainwire harness system like described above in the data communicationsstate machine example implementation. This functionality can allow eachpower supply module to learn about which other modules are present inthe system. Each module can take turns asserting the synchronizationsignal, in order of the manufacturing serial number. Each module canverify that it can detect the synchronization test pulses for theexpected number of modules, otherwise the system can be faulted. Anexample wire-or synchronization system verification operation isprovided below.

SYNC Testing State Machine

-   -   1) Wait for data comms complete    -   2) loop for 1 to module count        -   a. If SN order=loop count then assert sync, else detect sync        -   b. Assert sync for assert-test time        -   c. De-assert sync for de-assert-test time        -   d. Detect sync            -   i. If sync not detected within detect-test time, then                -   1. Set sync testing fault                -   2. Sync testing done            -   ii. If sync detected, then                -   1. If loop count =roll-in count, then                -    a. sync testing done                -   2. If loop count 1=roll-in count, then                -    a. increment loop count    -   3) Sync testing done

FIGS. 4-9 show various example components of a wire harness, such as thewire harness 12, that can be used to connect individual power supplymodules of a power supply system. The components shown in FIGS. 4-9 canbe used in combination and/or separately, depending on the intendedconfiguration of the specific implementation of the power supply system.For simplification, FIGS. 4-9 show single lines in place of wire pairs.The components shown in FIGS. 4-9 are provided as examples, and it willbe appreciated that many different configurations and combinations ofthese components are possible, in addition to other possible types ofcomponents that can be used with a wire harness to connect power supplymodules in accordance with various aspects of the disclosure.

Referring specifically to FIG. 4 , an example wire harness assembly 32is shown. The wire harness assembly 32 can generally be a T-shapedcabinet harness that supports multiple system configurations with acommon harness configuration. The wire harness assembly 32 can bepre-installed in an electrical cabinet during manufacturing of the powersupply system. The power supply system including one or more powersupply modules can be implemented withing one electrical cabinet, orwithin multiple electrical cabinets. Each system cabinet can have aharness to support the cabinet fault daisy chain and pre-chargesynchronization interconnections between parallel modules. The cabinetharnesses can provide 240 Volts of AC power to the individual modules,in some implementations. The wire harness assembly 32 is shown toinclude both a synchronization bus (SYNC bus) and a fault bus (FaultLoopback). The fault bus and the synchronization bus can be connected toindividual modules via wire pairs. The synchronization bus signals goingto the left and to the right in each cabinet harness (sections of aninterconnected wire harness) can be separate wire pairs that areelectrically tied together by the main control board, rather than havinga “T” splice in the harness itself. This configuration can simplifyharness construction.

Referring specifically to FIG. 5 , an example bypass jumper 33 is shown.The bypass jumper 22 can be attached to the system cabinet and can tiethe synchronization bus wires together for N−1 operation. The bypassjumper 33 can be pre-installed during manufacturing, and located in aposition such that it may not be accessible when the power supply moduleis in the cabinet. In this sense, if an individual power supply moduleis removed from the power supply system, the bypass jumper 33 can beused to continue normal system operation with the remaining power supplymodules, such that the entire power supply system is not disabled anddoes not need to be entirely reconfigured and synchronized. Accordingly,using one or more bypass jumpers within the wire harness can provideimproved modularity and flexibility of the power supply system.

Referring specifically to FIG. 6 , an example loopback jumper 34 isshown. Loopback jumper 34 can be provided on either side of the “T”harness (shown in FIG. 4 ) when there is no adjacent system cabinet,such that fault signals provided on the fault bus can be looped back tothe power supply module at the opposite end of the daisy chain.Referring specifically to FIG. 7 , an example harness coupler 36 isshown. The harness coupler 36 can be used between adjacent systemcabinets, such that the coupler 36 connects the synchronization bus andthe fault bus of the system wire harness between cabinets (e.g., betweena first cabinet and a second cabinet).

Referring specifically to FIG. 8 , an example wiring bay adapter 40 andan example adapter 38 used to connect a thermal switch are shown. Wiringbay adapter 40 can be used to connect the system wire harness to awiring bay provided in an electrical cabinet, and adapter 38 can be usedto connect the system wire harness to a thermal switch. The connectionsto the wiring bay and the thermal switch can be used for fault detectionbecause of overtemperature, and for connecting various components of thepower supply system between one or more electrical cabinets in afacility. Referring specifically to FIG. 9 , an example wiring baypass-through device 50 is shown. The wiring bay pass-through device 50can be used to connect the power supply system synchronization andcabinet fault signals, for example. The wiring bay pass-through device50 can also be used to provide a common connection for busbar thermalswitches.

FIGS. 10-14D provide examples of different power supply systemconfigurations that can be implemented in accordance with aspects of thedisclosure. Each of the modules shown in FIGS. 10-14D can includeaspects of the modules and circuits shown and described above withrespect to FIGS. 1-3 , and each of the wire harnesses shown can includeone or more of the components shown and described above with respect toFIGS. 4-9 . For example, each of the power supply modules shown caninclude the power supply circuit 20 discussed above, and can beinterconnected via fault input and output terminals as discussed withrespect to system 10 above. The configurations shown and described withrespect to FIGS. 10-14D are provided as examples, and it will beappreciated that various power supply system configurations andassociated circuits can be implemented in accordance with aspects of thepresent disclosure.

Referring specifically to FIG. 10 , an example power supply system 60including a single power supply module 61, where power supply system 60does not have a wiring bay, is shown. As shown, power supply module 61includes a fault input terminal 64, a fault output terminal 65, asynchronization terminal 66, and a module control board 67. The modulecontrol board 67 can include one or more processors and memory, forexample, for implementing functionality discussed herein as well asadditional functionality. Also shown, the power supply module 61 isconnected to a wire harness 68 that includes both a fault bus 62 and asynchronization bus 63. The fault bus 62 can be connected to both thefault input terminal 64 and the fault output terminal 65 in thisconfiguration, where the fault bus 62 uses loopback jumpers likeloopback jumper 34. Power supply module 61 can be connected toadditional power supply modules via harness 68, such as discussed in theexample system configurations below.

Referring specifically to FIG. 11 , an example power supply system 70including two power supply modules is shown. As shown, a power module 71and a power module 72 are connected via a wire harness including a faultbus and a synchronization bus. Power supply system 70 can require awiring bay with a busbar overtemperature switch (not shown), in someimplementations. The hard fault output of the power supply module 71 isrouted through the wire via the fault bus harness to the cabinet faultinput of the power supply module 72. The hard fault output of the powersupply module 72 is looped back into the cabinet fault input of thepower supply module 71. The synchronization terminals of each of the twopower supply modules 71, 72 are wire-or'd together, so that pre-chargewill commence when both modules are ready.

Referring specifically to FIG. 12 , another example implementation ofthe power supply system 70 including a wiring bay 84 and thermal switch86 is shown. The hard fault output of the power supply module 71 isrouted through the wire harness into the cabinet fault input of thepower supply module 72. The hard fault output of the power supply module72 loops back to the left side, and then passes through a normallyclosed busbar overtemperature switch 86 before connecting into thecabinet fault input of the power supply module 71. If theovertemperature switch 86 opens due to high temperature (e.g., sensing atemperature above a threshold level), it will interrupt the cabinetfault signal. The cabinet fault input of the power supply module 80 canbe triggered either by the hard fault output of the power supply module72, or by the overtemperature switch 86 in the wiring bay 84. Wiring bay84 can be implemented using wiring bay adapter 40 and adapter 38 asdiscussed above with respect to FIG. 8 , for example. Thesynchronization terminals of each of the two power supply modules 71, 72are wire-or' d together, so that pre-charge will commence when bothmodules are ready.

Referring specifically to FIGS. 13A-13D, another example power supplysystem 90 is shown. Power supply system 90 includes six power supplymodules with two wiring bays. From the leftmost module 91, each hardfault output terminal is routed through the harness into the cabinetfault input of the next right module. The cabinet fault signal passesthrough the overtemperature switches of the two wiring bays 94, 96 nearthe center of the system. Depending on the application, two wiring bayovertemperature connectors (e.g., like adapter 38) can be used on asingle harness as shown in FIG. 13B and FIG. 13C. A second thermalswitch can also be connected to the second wiring bay overtemperatureconnectors shown. A single overtemperature connector can also be useddepending on the application. If an overtemperature switch opens, itwill interrupt the cabinet fault signal on the fault bus. The hard faultoutput of the rightmost module 98 is looped back into the cabinet faultinput of the leftmost module 91. A cabinet input to a module is onepossible source of a module hard fault output. This causes any hardfault source to automatically cascade through the daisy-chain of allpower supply modules of the system. All power modules can display acabinet fault (system level fault), but the power module with theoriginal hard fault source (device level fault) will also display thecorresponding fault code. If none of the power modules display anythingbut a cabinet fault, then the source of the fault is either an openwiring bay overtemperature switch, unplugged connection, or faultyconnection contact. The synchronization terminals of all six powersupply modules in power supply system 90 are wire-or'd together, so thatpre-charge will commence when all of the modules are ready.

Referring specifically to FIGS. 14A-14D, another example power supplysystem 100 is shown. In contrast to the power supply system 90 shown inFIGS. 13A-13D, in the power supply system 100, one of the six powersupply modules has been removed from the system, and its connectionsreplaced by a bypass jumper 104. As such, the power module system 100 isconfigured to operate in an N−1 operation of the system at a reducedcapacity. The bypass jumper 104 can be connected in place of the removedpower supply module to complete the cabinet fault signal chain. Thesystem can include a bypass jumper mounted in each cabinet that themodule normally blocks access to. This design enables bypass jumpers tobe readily available when modules are removed. This design can alsoprevent having the bypass inadvertently connected when the removedmodule is in place. Multiple power supply modules can be removed andbypassed (e.g., N−2, N−3, etc. down to the case where only a singlepower supply module remains).

While the present disclosure can be susceptible to various modificationsand alternative forms, specific embodiments have been shown by way ofexample in the drawings and have been described in detail herein.However, it should be understood that the present disclosure is notintended to be limited to the particular forms disclosed. Rather, thepresent disclosure is intended to cover all modifications, equivalents,and alternatives falling within the spirit and scope of the presentdisclosure as defined by the following appended claims. The techniquespresented and claimed herein are referenced and applied to materialobjects and concrete examples of a practical nature that demonstrablyimprove the present technical field and, as such, are not abstract,intangible or purely theoretical.

1. A power supply system comprising: a first power supply modulecomprising a first fault input terminal, a first fault output terminal,and a first synchronization terminal; a second power supply modulecomprising a second fault input terminal, a second fault outputterminal, and a second synchronization terminal; and a wire harness thatconnects the first power supply module and the second power supplymodule, the wire harness comprising a synchronization bus and a faultbus; wherein the synchronization bus is connected to the firstsynchronization terminal and the second synchronization terminal; andwherein the fault bus connects the first fault output terminal to thesecond fault input terminal and the second fault output terminal to thefirst fault input terminal.
 2. The system of claim 1, wherein the firstpower supply module comprises circuitry configured to assert a firstsynchronization signal on the synchronization bus and the second powersupply module comprises circuitry configured to assert a secondsynchronization signal on the synchronization bus.
 3. The system ofclaim 2, wherein the system initiates a concurrent precharge process forthe first power supply module and the second supply module responsive tothe first power supply module asserting and de-asserting the firstsynchronization signal on the synchronization bus and the second powersupply module asserting and de-asserting the second synchronizationsignal on the synchronization bus.
 4. The system of claim 2, wherein thecircuitry of the first power supply module comprises an optocouplerconnected to a resistor ladder, and wherein the circuitry of the firstpower supply module is configured to assert the first synchronizationsignal on the synchronization bus when the optocoupler is energized andcompletes a circuit with the resistor ladder.
 5. The system of claim 4,wherein the first synchronization signal comprises a current signalprovided at the first synchronization terminal via a first wireconnected to a first terminal of the optocoupler and a second wireconnected to a second terminal of the optocoupler.
 6. The system ofclaim 2, wherein the circuitry of the first power supply modulecomprises a first optocoupler connected to a resistor ladder and asecond optocoupler connected to a transistor, wherein the circuitry ofthe first power supply module is configured to assert the firstsynchronization signal on the synchronization bus when the firstoptocoupler is energized, and wherein the circuitry of the first powersupply module is configured to energize the second optocoupler toindicate a synchronization status of the first power supply module. 7.The system of claim 6, wherein the resistor ladder is connected to thetransistor.
 8. The system of claim 1, wherein the first power supplymodule and the second power supply module are both contained within asingle cabinet, and wherein the wire harness comprises a loopbackjumper.
 9. The system of claim 1, wherein the first power supply moduleis contained within a first cabinet and the second power supply moduleis contained within a second cabinet, and wherein the wire harnesscomprises a coupler that connects the synchronization bus and the faultbus between the first cabinet and the second cabinet.
 10. The system ofclaim 1, wherein the wire harness comprises a normally closed thermalswitch connected to the fault bus.
 11. The system of claim 1, whereinthe first power supply module is configured to transmit a first serialnumber to the second power supply module via the wire harness and thesecond power supply module is configured to transmit a second serialnumber to the first power supply module via the wire harness, andwherein the system uses the first serial number and the second serialnumber to verify proper configuration of the system upon power up. 12.The system of claim 1, wherein the first power supply module comprisescircuitry configured to identify a system level fault based on a signalreceived via the fault bus at the first fault input terminal and toindicate a device level fault by transmitting a signal via the firstfault output terminal to the fault bus.
 13. A power supply systemcomprising: a first power supply module comprising a first fault inputterminal, a first fault output terminal, and a first synchronizationterminal; a second power supply module comprising a second fault inputterminal, a second fault output terminal, and a second synchronizationterminal; a third power supply module comprising a third fault inputterminal, a third fault output terminal, and a third synchronizationterminal; and a wire harness that connects the first power supplymodule, the second power supply module, and the third power supplymodule, the wire harness comprising a synchronization bus and a faultbus; wherein the synchronization bus is connected to the firstsynchronization terminal, the second synchronization terminal, and thethird synchronization terminal; and wherein the fault bus connects thefirst fault output terminal to the second fault input terminal, thesecond fault output terminal to the third fault input terminal, and thethird fault output terminal to the first fault input terminal.
 14. Thesystem of claim 13, wherein: the first power supply module comprisescircuitry configured to assert a first synchronization signal on thesynchronization bus; the second power supply module comprises circuitryconfigured to assert a second synchronization signal on thesynchronization bus; the third power supply module comprises circuitryconfigured to assert a third synchronization signal on thesynchronization bus; and the system initiates a concurrent prechargeprocess for the first power supply module, the second supply module, andthe third power supply module responsive to the first power supplymodule asserting and de-asserting the first synchronization signal onthe synchronization bus, the second power supply module asserting andde-asserting the second synchronization signal on the synchronizationbus, and the third power supply module asserting and de-asserting thethird synchronization signal on the synchronization bus.
 15. The systemof claim 14, wherein the circuitry of the first power supply modulecomprises an optocoupler and the first synchronization signal comprisesa current signal provided at the first synchronization terminal via afirst wire connected to a first terminal of the optocoupler and a secondwire connected to a second terminal of the optocoupler.
 16. The systemof claim 13, wherein the first power supply module comprises circuitryconfigured to identify a system level fault based on a signal receivedvia the fault bus at the first fault input terminal and to indicate adevice level fault by transmitting a signal via the first fault outputterminal to the fault bus.
 17. The system of claim 13, wherein the wireharness comprises a normally closed thermal switch connected to thefault bus.
 18. A power supply system comprising: a first power supplymodule comprising a first fault input terminal, a first fault outputterminal, and a first synchronization terminal; a second power supplymodule comprising a second fault input terminal, a second fault outputterminal, and a second synchronization terminal; and a wire harness thatconnects the first power supply module and the second power supplymodule, the wire harness comprising a synchronization bus and a faultbus; wherein the synchronization bus is connected to the firstsynchronization terminal and the second synchronization terminal;wherein the fault bus connects the first fault output terminal to thesecond fault input terminal and the second fault output terminal to thefirst fault input terminal; wherein the first power supply modulecomprises circuitry configured to assert a first synchronization signalon the synchronization bus; and wherein and the second power supplymodule comprises circuitry configured to assert a second synchronizationsignal on the synchronization bus.
 19. The system of claim 18, whereinthe system initiates a concurrent precharge process for the first powersupply module and the second supply module responsive to the first powersupply module asserting and de-asserting the first synchronizationsignal on the synchronization bus and the second power supply moduleasserting and de-asserting the second synchronization signal on thesynchronization bus.
 20. The system of claim 18, wherein the circuitryof the first power supply module comprises an optocoupler and the firstsynchronization signal comprises a current signal provided via a firstwire connected to a first terminal of the optocoupler and a second wireconnected to a second terminal of the optocoupler.